Molding System for Fungal Structures

ABSTRACT

A molding system for forming an inoculated lignocellulose based medium into a fungal molded shape, the molding system comprising a vessel within which environmental conditions are regulated, the vessel comprising an inoculated lignocellulose based medium capable of supporting growth of saprophytic fungi without any secondary organisms displacing the process through infection a secondary organic material layered near the top and bottom of the inoculated lignocellulose based medium, a hard mold containing the flexible vessel; and a compressive system for applying a primary compressive pressure of at least 10 PSI to the lignocellulose based medium such that it takes on a fungal molded shape.

RELATED APPLICATIONS

This application is a continuation application of U.S. patentapplication Ser. No. 15/230,438 filed Aug. 7, 2016, and which is acontinuation application of U.S. patent application Ser. No. 13/305,576filed Nov. 28, 2011 and granted Aug. 9, 2016 as U.S. Pat. No. 9,410,116,and which claims priority from U.S. provisional application with Ser.No. 61/417408, which was filed on Nov. 27, 2010. The disclosures ofthese applications are incorporated herein as if set out in full.

BACKGROUND OF THE DISCLOSURE Technical Field of the Disclosure

The present embodiment relates in general to methods for creatingorganically derived building materials using the growth of fungaltissue. More specifically, the present embodiment relates to a methodfor growing engineered building materials in the form of a moldablesubstrate which can be used for a wide range of manufacturing andconstruction applications.

Description of the Related Art

Fungi are a kingdom of organisms which are numerous and diverse, and aredistinguished in part by the habits and forms of representative members'vegetative growth and reproduction. While fungi are increadibly diversein form, habit, and environemtal requirements, fungi are easilyidentifiable by the shared common trait of consuming living or onceliving organic matter. Like animals, fungi feed on the bodies of otherorganisms as their primary source of constituent matter and energy, andare the primary decomposers and recyclers of materials on the planet.Fungi are distributed through the depths of the ocean, within andamongst the bodies of all the higher organisms, and have spores thattravel to the heights of the atmosphere and out into space. The sporesof fungi are resilient enough to enter the vacume of space and return toearth, growing once again when situated in welcoming terrestrialconditions.

One of the primary forms of material that fungi assist in decomposingare the plants, trees and other organisms that weave airborn carbon intoa terrestrial form with energy derived from sunlight. Chlorophyl basedorganisms transform sunglight into the sugars, carbohydrates and othermacromolecules that consitiute a plant's various cells, tissues andorgans. Many of these sugars in plants are tightly bound within the formof lignin and cellulose, which are composed from an intricately linkedglucose based polymer, the constituent element of which comprises thedense structural elements of the plant's body. Many different kinds offungi have evolved the ability to break down both lignin and cellulose,and transform it into chitin, the resiliently hard molecule that fungiuse to build their cell walls. Fungi are both strong and flexible, andare capable of synthesizing (and also metabolizing) a wide range ofenzymes, oxidative compounds, alcohols and other caustic chemical agentsthat can break the strong hydrogen bonds that contribute to the rigidityand strucutre of cellulose. Many fungi that feed upon cellulose infectand colonize their preferred nutrient source by means of hyphal cellsthat grow in a vegatative manner from the apical ends of the cell. Thesehypha are characterized by apical growth patterns that includebifurcations, ramifications and other branching cellular nodes that arecapable of secreting and reabsorbing the above mentioned caustic agents,and are capable of breaking down and digesting the hardest known woods.These growing nodes increase the area and potential connectivty of thecolective hyphal structures, allowing the fungal cells to infiltrate,connect and modify a wide range of endogenous environments that it mightbe situated within. The Polypores are a group of fungi that are knownfor their durabiliy, strength and long life span. The polypores are widein their geographic distribution and can breakdown and utilize a widerange of plant life that is rich in sources of lignin and cellulose.

In recent years fungi have come to be an accepted material for a rangeof consumer and building applications, and are increasingly being usedin the place of plastics, urethanes and other fossil fuel dependentcompounds. In addition to its strength and durability, dried fungus hasmany other beneficial qualities: it is nontoxic, fire-resistant, moldresistant, water-resistant and a great thermal insulator amongst othersalient features. Fungi can be processed with less energy and materialsthan conventional manufactuing, and can be grown in a way thatcontributes to good stewardship of renewable resources. Differentmethods have been developed to utilize the fungi's capabilities forrapidly digesting and transforming a range of biological materials, yetall are due in great part to the physical characteristics of the growinghyphal cells of the fungi, which form a complexly interwoven tissue thatis called mycelium.

This mycelial web can be as strong and resilient as wood, and acts as abonding agent for a wide range of materials that it might beincorporated within. The mycelium itself is remarkably sensitive tolocal environmental conditions, and the current state of the art isadvancing with new means for adjusting and modifying this environment inways to cause the fungus to grow in a desired manner and with desiredcharacteristics. The state of the art in this field is new and primarilyconsists of simple molds and laminated substrates, and there is a needfor innovative techniques in both the forming, conditioning andmanufactuing of the growing fungi and the material that it generates.

Recent advancements in the art include a fungus that is grown for thepurposes of providing a polystyrene replacement that is based uponorganically derived materials and feedstock. This method involvesplacing fungus and agricultural or industrial waste products such asrice husks, wheat husks or sawdust into a mold in the form of a panelwherein incubation occurs for several days. During the incubation periodthe inoculated fungal substrate forms a mycelial network that binds thematerials together, slowly solidifying into the shape of the form it wascast within. After incubation, the entire mixture may be dried so thatfurther fungal growth is retarded. The finished panel product exhibitsthe characteristics of the original materials it was grown from (such asthe strength or thermally insulating qualities of the fibers), which arenow “glued” together by the fungus. Though a good insulator, this panelmust be formed in combination with a laminated back or sandwich of athin, rigid material when greater tensile strength is desired. The finalproducts made through this process are lightweight, and when itsconsumer cycle is complete it can be added to landfill or compost due tothe sole use of natural ingredients. The product has also been used as areplacement for Styrofoam packaging, both with and without rigidbackings, and will soon be available as home and building insulation.This method does not however provide a means for producingenvironmentally friendly building materials that are also strong anddurable enough for the tolerances and demands of many othermanufacturing and construction applications than a fragile Styrofoamtype formulation.

Another existing system uses mycelium to create materials composed of ahybrid fungal tissue. This method includes the steps for forming aninoculum, which includes a preselected fungus, to form a mixture of asubstrate of discrete particles and a nutrient material that is capableof being digested by the fungi. The inoculum is added to the mixture andallows the fungus to digest the nutrient material in the mixture over aperiod of time sufficient to grow hyphae. The hyphae form a network ofinterconnected mycelia cells through and around the discrete particlesto form a self-supporting composite material. This self-supportingcomposite material is heated to a temperature sufficient to kill thefungus or otherwise dried to remove any residual water to prevent thefurther growth of hyphae. The method allows for placing the mixture andinoculum in a mold of any desired shape so that the finished compositematerial takes on that determined form. The downside to this system isthat the fungus must colonize its substrate and incorporate into asolidified form within its carrying mold, limiting production speeds andutilizing one mold per manufactured unit. This method is not conduciveto the demands of fast throughput manufacturing and processing that willbe needed to make this an economically competitive material.

There are several other methods that have been developed to grow fungusfrom agricultural and wood industry by-products, using aerated fungalfoams, liquid aggregates and the inclusion of secondary reinforcingparticles, fibers and other ingredients to aid in making stronger, moreresilient materials. Such methods introduce the fungal inoculum into anaerated growth medium, which may include other additional materials suchas nutritional supplements or binding and filling agents. The fungalinoculum grows through the foam and binds together its includedingredients into a dense yet flexible material once it has been curedand dried. In one example the method uses different growth mediums suchas microcrystalline cellulose mixed with water and nutrients as asupport substrate through which the fungal hyphae grow, and as a resultrendered into a constituently solidified artifact. After a drying andcuring process these fungal foams that include added particles andfibers exhibit increased mechanical strength and flexibility and haveother beneficial qualities. This method is limited in application as thesize with which one might construct individual components is restrictedin volume and mass to small things (2″ cubed). While fungal componentsmay be grown together into larger composite pieces, substrate thicknessis usually limited to 6″ in depth due to the anaerobic conditions canarise in samples that are too dense to allow the free exchange ofpermeable gases between the fungal substrate and the environment it isgrowing within. This condition gives rise to anaerobic zones within thefungal substrate, making it susceptible to infection by microbes thatfavor these types of environments. Thus, most of these cured fungalfoams that include particles and fibers are limited to being grown inparts that are too small for use in home construction and many otherindustrial applications.

The environmental benefits of utilizing fungus for the growth ofbuilding blocks and other manufacturing materials might be significantin consideration of the impact and potential use of agricultural waste.As a byproduct of growing and producing food worldwide, humans create avast amount of agricultural waste that would otherwise be unused,returning vast quantities of carbon and other materials duringdegradation and decomposition. Such agricultural waste may be viewed asfood for a fungus. Hence, it can be seen, that there is a need fordeveloping environmentally friendly materials that might replacetraditionally used non-biodegradable durable and strong materials, suchas plastics and composites. This method would create stronger and densebuilding blocks, which can be easily molded and cheaply preprocessed toprecise geometric specifications. In addition, this method would make itpossible to construct highly complex, structured building blocks whichmight be arranged and joined with each other to comprise structurallyengineered manufacturing components and larger artifacts on the scale ofbuildings from environmentally friendly materials. More importantly, thebuilding blocks created through this method may be completelybiodegradable.

While the above benefits are apparent there is also a need forsimplification in the prior art. There is a further need to increaseperformance of the finished product, such as adhesion strength, andcompressive capabilities—all without increasing the weight of thematerial.

The Applicant has discovered that the application of compressivepressure at points throughout the process, either to the lignocellulosebased medium or the growing fungal mycelium, results in vastly increasedstrength, durability and adhesion characteristics. This processadditionally speeds production time and allows for the creation of muchlarger fungal objects.

SUMMARY OF THE DISCLOSURE

The present invention provides a method for growing organically derivedbuilding materials in the form of a moldable substrate which can beengineered to serve a wide range of manufacturing and constructionapplications.

The present invention discloses obtaining a lignocellulose based mediumthat is conducive towards the growth of fungal vegetative growth, mixingsaid lignocellulose based medium with water until a desired hydrationlevel is reached, optionally pasteurizing said lignocellulose basedmedium, and inoculating said lignocellulose based medium with fungalinoculum and allowing time for said inoculated lignocellulose basedmedium to become colonized to the extent that said inoculatedlignocellulose based medium is permeated with fungal mycelium withoutany secondary organisms displacing the process through unwantedinfection.

During the vegetative growth of the fungal mycelium it is important tomaintain an environment and conditions that are conducive to theorganism's growth patterns. Thus, the area the fungi are growing withinwill take into consideration the provision of favorable temperatures,light levels, humidity and gas exchange and other factors, while alsoprotecting the growing fungal mass from infectious agents and organismsthat might consume its cells and tissues.

The above steps may occur within a vessel or alternatively on a flatsurface, such as a table or conveyer belt, and even after the hydratedsubstrate has been formed into a condensed and pressed form. Thelignocellulose-based medium may be placed into a mold so that thecolonized fungal substrate forms into a molded fungal shape. In eachcase, a primary compressive pressure of at least 100 PSI and preferablyat least 500 PSI is applied to the lignocellulose-based medium orcolonized fungal mycelium before being reduced by a factor of at least 4and preferably 20. Secondary and tertiary pressures may be appliedthroughout the process.

Compression confers vast improvements in the fungal material's abilityto withstand dynamic forces, with observations of improvements a factorand better against controls. Compressive strength was found to be 6×over non-compressed, and flexural strength up to a factor.

In another aspect of the present invention, in accordance with thepresent invention is a method for growing organically derived buildingmaterials in the form of a moldable substrate which can be engineered toserve a wide range of manufacturing and construction applications.

A first objective of the present invention is to provide a durableindustrial grade material that may serve a wide range of manufacturingand construction applications.

A second objective of the present invention is to provide stronger andmore complexly engineered structured blocks for use in industrial andbuilding applications.

A third objective of the present invention is to provide a fungalsubstrate, which could be molded, and easily and cheaply preprocessedand finished to precise geometric specifications.

Yet another objective of the invention is to provide a plurality offungal molded shapes in which layers of structural reinforcements orfacings may be incorporated to improve load bearing and other structuralcapacities.

Still another objective of the invention is to provide buildingmaterials that are fire resistant, water resistant, and mold resistant,are good insulators and other beneficial properties.

These and other advantages and features of the present invention aredescribed with specificity so as to make the present inventionunderstandable to one of ordinary skill in the art.

BRIEF DESCRIPTION OF THE DRAWINGS

In order to enhance their clarity and improve understanding of thesevarious elements and embodiments of the invention, elements in thefigures have not necessarily been drawn to scale. Furthermore, elementsthat are known to be common and well understood to those in the industryare not depicted in order to provide a clear view of the variousembodiments of the invention, thus the drawings are generalized in formin the interest of clarity and conciseness.

FIG. 1 is an exemplary and preferred embodiment of the method forgrowing organically derived building materials in the form of a moldablesubstrate which can be engineered to serve a wide range of manufacturingand construction applications;

FIG. 2 is an exemplary and alternative operational flow chart of amethod for growing organically derived building materials in the form ofa moldable substrate which can be engineered to serve a wide range ofmanufacturing and construction applications in accordance with thepresent invention;

FIG. 3 illustrates a mold used to form a fungal molded shape inaccordance with the exemplary embodiment of the present invention;

FIG. 4 illustrates a plurality of fungal molded shapes formed by themold in accordance with the exemplary embodiment of the presentinvention;

FIG. 5 illustrates the plurality of fungal molded shapes assembledtogether in a wall formation, wherein one exemplary brick is depictedapart from the wall;

FIG. 6 illustrates the plurality of fungal molded shapes incorporatedwith a plurality of dowels to create structural connections inaccordance with the exemplary embodiment of the present invention;

FIG. 7 illustrates a the construction of an archway formed by placingthe plurality of fungal molded shapes in proximal contact with oneanother to form an organic bond in accordance with the exemplaryembodiment of the present invention;

FIG. 8 illustrates the construction of a wall like structure formed byplacing the plurality of fungal molded shapes in proximal contact withone another to form an organic bond in accordance with the exemplaryembodiment of the present invention;

FIG. 9 illustrates secondary materials incorporated into the fungalmycelium to create structural connections in accordance with theexemplary embodiment of the present invention;

FIG. 10 illustrates a two tab fixturing element incorporated directlyinto the fungal molded shape in accordance with another aspect of theexemplary embodiment of the present invention;

FIG. 11 illustrates a plurality of fungal molded shapes formed with castvoid spaces in accordance with the alternate embodiment of the presentinvention; and

FIG. 12 includes four images taken as steps in a process from left toright, wherein a vessel is depicted holding a fungal molded shape, thena piston is shown compressing said shape such that outgassing occurs,then upon release of the piston ingassing is apparent as the shapenaturally rebounds to some extent, resulting in the final image on theright hand side of the figure.

DETAILED DESRIPTION OF THE DRAWINGS

In the following discussion that addresses a number of embodiments andapplications of the present invention, reference is made to theaccompanying drawings that form a part hereof, and in which is shown byway of illustration specific embodiments in which the invention may bepracticed. It is to be understood that other embodiments may be utilizedand changes may be made without departing from the scope of the presentinvention.

Various inventive features are described below that can each be usedindependently of one another or in combination with other features.However, any single inventive feature may not address any of theproblems discussed above or only address one of the problems discussedabove. Further, one or more of the problems discussed above may not befully addressed by any of the features described below. Finally, many ofthe steps are presented below an order intended only as an exemplaryembodiment. Unless logically required, no step should be assumed to berequired earlier in the process than a later step simply because it iswritten first in this document.

An exemplary embodiment of the present invention considers a method forgrowing organically derived building materials in the form of a moldablesubstrate which can be engineered to serve a wide range of manufacturingand construction applications. Referring to FIG. 1, an operational flowchart of the method for growing organically derived building materialsin the form of a moldable substrate which can be engineered to serve awide range of manufacturing and construction applications isillustrated. Initially, a lignocellulose based medium that is conducivetowards the growth of fungus is obtained, as shown at block 1. Oneconducive and capable of growing said fungi will have proper amounts ofmicronutrients, nitrogen, trace elements, and/or vitamins as is known inthe art. If said amounts are not present, they may be added to saidlignocellulose based medium. Said lignocellulose based medium is mixedwith water until a desired hydration level is achieved as indicated atblock 2. As an example of steps in this invention that may be taken inany order unless logically required, water may be mixed with saidlignocellulose based medium at the same time that micronutrients,nitrogen, trace elements and/or vitamins are added, or even after. Saidlignocellulose based medium may be pasteurized for a specific time.After, during, and/or before pasteurization, introduction of a fungalinoculum to the lignocellulose based medium is initiated, as shown inblock 3. Then, as indicated at block 4, the selected fungus is allowedto be successfully introduced into the hydrated media. Time is allowedfor the inoculated lignocellulose based medium to become colonized tothe extent that the inoculated lignocellulose based medium is permeatedby fungal mycelium without any secondary organisms displacing theprocess through infection, as shown in block 5. Colonization is completeenough that secondary organisms are unable to displace this processthrough infection.

In this embodiment a vessel is provided in which colonization may occur.The fungal mycelium may be placed into a mold so that the fungalmycelium forms into a fungal molded shape as shown and described inblock 6. In this method, a primary compressive pressure of at least 100PSI (and more preferably at least 500 PSI, and in other cases at least2000 PSI) is applied to the fungal mycelium as shown in block 7. Inother embodiments, said primary compressive pressure can be at least 100PSI. The amount of time the pressure is applied and the step at whichpressurization occurs are variable. For instance, primary compressivepressure may be applied at any of the steps prior to inoculation.Preferably, however, and in this embodiment, the primary compressivepressure is placed on the fungal mycelium as it is in the mold. Saidprimary compressive pressure is then reduced by a factor of at least 4,but preferably at least 20 as indicated at block 8. In a preferredembodiment pressure is reduced to ambient environment pressure, which atsea level at 15 degrees Celsius is 760 mmHg, or around 14.696 PSI. Saidfungal molded shape is removed from said mold after said placing step asshown in block 9. As indicated at block 10, said fungal molded shape isdried at a specific temperature for a specific time period. Steps shownin blocks 11 (rehydration and/or pressure and/or drying) and 12 (curing,terminating biological activity, material finishing) are described indetail later in this document.

In this method, the fungal molded shape forms the organically derivedbuilding material. The environmental conditions in the vessel areregulated by providing a regulatable relationship between said vesseland the outside environment, as described below. Thelignocellulose-based medium is mixed with water to provide a sufficientamount of water to adequately hydrate the lignocellulose-based medium.The pasteurizing step, if present, should be terminated subsequent tothe termination of said mixing step. The lignocellulose substrate basemay be pasteurized using heat pasteurization and the vessel may becooled subsequent to said pasteurizing step. The method also provides abuffer to balance the pH of the lignocellulose-based medium. The fungalinoculum allows the growth of the tissue of the selected fungus to beadministered through, in, or on the lignocellulose substrate. Inaddition, a secondary compressive pressure, at least 100 PSI, is appliedto the fungal molded shape after the fungal molded shape is removed fromthe mold. The secondary compressive pressure may be physically appliedusing any suitable means, such as a compressive piston or a roller suchas a stationary roller on a moving conveyer belt holding the fungalmolded shape. The secondary compressive pressure is then released andthen a tertiary compressive pressure of at least 100 PSI may be appliedto the fungal molded shape. Additional increases and decreases ofpressure are optional. The pressure may be sufficient to cause saturatedwater within the fungal molded shape to be forced out, thereby allowingthe fungal molded shape to absorb an agent, either fluid or gas, asshown in FIG. 13 and described in the accompanying text. The method maybe further accompanied by pulverizing said fungal molded shape into aplurality of small pieces. As with many steps in this process,pulverization does not necessarily occur either before or after anyother compression step.

Turning now to FIG. 2, an operational flow chart for a method forgrowing organically derived building materials in the form of a moldablesubstrate which can be engineered to serve a wide range of manufacturingand construction applications in accordance with an aspect of theexemplary embodiment of the present invention is illustrated. Initially,a lignocellulose based medium that is conducive towards the growth offungus is obtained, as shown at block 101. One conducive and capable ofgrowing saprophytic fungi will have proper amounts of micronutrients,nitrogen, trace elements, and/or vitamins as is known in the art. Ifsaid amounts are not present, they may be added to said lignocellulosebased medium. Said lignocellulose based medium is mixed with water untila desired hydration level is achieved as indicated at block 102.Preferably, the hydration level is approximately 66%. That is, the totalweight after hydration is composed of 2 parts water for every 1 partlignocellulose based medium. Other options might include a range of33-66% hydration, and in some cases, 25-75%.

Said lignocellulose based medium may optionally be pasteurized for aspecific time. Whether pasteurized or not, the lignocellulose basedmedium may be inoculated with a fungal inoculum 103 to create a fungalmycelium such that the tissue of the fungal inoculum grows through andfully colonizes said fungal mycelium as shown in block 104. In thismethod time is allowed for said inoculated lignocellulose based mediumto become colonized to the extent that said inoculated lignocellulosebased medium is transformed into a fungal mycelium without any secondaryorganisms displacing the process through infections, as indicated atblock 105. Then, environmental conditions surrounding the inoculationprocess are strictly regulated and the fungal mycelium is allowed togrow.

A pressure is added on the growing fungal mycelium to at least 100 PSIas shown in block 107. In this method, a primary compressive pressure ofat least 500 PSI is applied to the fungal mycelium. In otherembodiments, said primary compressive pressure can be at least 100 PSI.The amount of time the pressure is applied and the step at whichpressurization occurs are variable. For instance, primary compressivepressure may be applied at any of the steps prior to inoculation.Preferably, however, and in this embodiment, the primary compressivepressure is placed on the fungal mycelium as it moves down on acontinuous feed system, such as a conveyer belt of assembly line.Pressure may be applied through a mechanical press, roller, or othersuitable compressing means used in continuous feed systems. The appliedpressure on the growing fungal mycelium is reduced as indicated at block108, preferably by a factor of 20, and less preferably by a factor of atleast 4. Preferably, pressure is set at ambient environmental pressureas described above with regard to the first embodiment. Said colonizedfungal mycelium is dried for a specific time period as shown in block109. The method may be further accompanied by pulverizing said fungalmycelium into a plurality of small pieces. As with many steps in thisprocess, pulverization does not necessarily occur either before or afterany other compression step.

As with the first embodiment described above, a secondary compressivepressure, at least 100 PSI, may be applied during this process. This mayoccur before or after drying. The secondary compressive pressure may bephysically applied using any suitable means as described above in thisembodiment and with regard to the first compressive pressure. Thesecondary compressive pressure is then released and then a tertiarycompressive pressure of at least 100 PSI may be applied to the fungalmolded shape in the same manner. Additional increases and decreases ofpressure are optional.

Any of the first, second, third, compressive pressures may be sufficientto cause saturated water within the fungal molded shape to be forcedout, thereby allowing the fungal molded shape to absorb an agent, eitherfluid or gas, as shown in FIG. 13 and described in the accompanyingtext.

FIG. 3 illustrates a mold 140 used to form an example fungal moldedshape 142 in accordance with the exemplary embodiment of the presentinvention. In this exemplary embodiment, the fungal mycelium forms afungal molded shape. The vessel is kept in a growing room having atemperature of between 55 and 90 degrees Fahrenheit. The vessel may beof nearly any volume, including containers such as a large room or anentire building, and may be either rigid or soft and flexible. The hardvessel may be a thermoplastic mold and the soft vessel may be a bag madeof plastic or polyethylene. The use of thermoplastic molds allows formore complex geometries, greater consistency in shape of the producedblocks, and larger forms. The growing room should have a regulatableenvironment as far as ambient and desired gas levels are concerned (O²,CO², etc.), temperature, humidity and light levels. The environmentalconditions of the growing room are regulated by providing a regulatablerelationship between the vessel and outside environment. During thevegetative growth of the fungal mycelium it is important to maintain anenvironment and conditions that are conducive to the organism's growthpatterns. Thus, the area the fungi are growing within will take intoconsideration the provision of favorable temperatures, light levels,humidity and gas exchange, while also protecting the growing fungal massfrom infectious agents and organisms that might consume its cells andtissues.

The vessel may comprise a flexible breathable filter membrane orflexible breathable filter membrane patch to allow for gas exchangewhile preventing unwanted bacteria and microorganisms from infectingsaid growing fungal substrate. When the fungal inoculum has fullycolonized the contents of the mold, the fungal molded shape is solidenough to take out of the mold 140. The lignocellulose-based medium isplaced into the mold 140 so that the colonized fungal substrate formsinto a fungal molded shape. The mold 140 may be selected from a groupconsisting of a wooden mold and a thermoplastic mold. Next, theplurality of fungal molded shapes is dried using any known method fordrying structures. In one embodiment, placing the fungal molded shapesin an 80-90 degrees Fahrenheit areas and using dehumidifiers and fans toaccelerate the process is used. Drying may be accompanied by dehydrationof the fungal molded shape such that water weight of said fungal moldedshape is at most 15% of the total weight of said fungal molded shape.Drying with heat may make the fungal inoculum biologically inert. Othermethods for drying involve chemically killing the fungal mycelium(through any known biocide, fungicide, alcohol etc.), microwaves, oreven smoking. In the smoking process, the fungal mycelium is dried andcured similarly to the common process for flavoring, cooking, orpreserving foodstuff. Drying may also be done in conjunction withcontinuous or pulsed application of linear pressure, which would resultin a thinner and denser building material. This type of drying may beemployed for the manufacture of consumer electronics such as phonecasings. This process may be used in combination with others describedin this patent application, such as the uptake of agents throughcompression and natural re-expansion.

FIG. 4 illustrates a plurality of fungal molded shapes 142 formed by themold 140 in accordance with the exemplary embodiment of the presentinvention. When the fungal inoculum has fully colonized the contents ofthe mold, the plurality of fungal molded shape 142 is solid enough totake out of its mold. At this point, the fungal molded shapes 142 may bedried as individual fungal molded shape, or placed in proximal contactwith one another such that an organic bond forms between each of theplurality of fungal molded shapes 142. Each of the plurality of fungalmolded shapes 142 comprises an outer surface of mycelium, and whereineach said outer surface fuses with the other to form an organic bond.The surface of the fungal molded shapes 142 forms a skin duringcolonization. The properties of this skin, such as consistency,strength, and density, may be manipulated by changing temperatures,light levels, gas concentrations, and photo periods during thecolonization period and after for any continued length of time. Thefungal inoculum may be a compressed form of mycelium fungi. The fungalinoculum may be selected from the group consisting of: Ganodermalucidem, Ganoderma tsugae, Ganoderma oregonense, Fomes fomentarius,Trametes versicolor and Piptoporous betulinus. The colonized oruncolonized substrate is combined with materials to change qualities andattributes of the growing fungus and the substrate composition. Thematerials for combining may be selected from the group consisting ofsilica, perlite, methylcellulose, glycerin, agarose, or any othermaterials that retain liquids through hydrophilic carrying capacitiesand demonstrable qualities of enhanced or desirable viscosity.Preferably the materials are all inert cellular material and retainliquids through hydrophilic carrying capacities and demonstrable viscousqualities.

FIG. 5 illustrates the plurality of fungal molded shapes 142 assembledtogether to make a larger structure 144 in accordance with the exemplaryembodiment of the present invention. The fungal molded shapes 142 may bejoined together to make larger structure 144. It is possible tofabricate a wide set of complexly assembled structures from a modularvocabulary of interlocking forms. Adhesion between individual fungalmolded shapes can be engineered for specific interfaces and connections,with defined planes, edges, bevels, mounts, or other fixturing elementsthat may distribute forces between and amongst conjoined modules. Onceassembled, these forms may organically weld to one another to createeven more complex structural assemblies, as described below.

Silica, perlite, clay and other biologically inert materials may beadded to the lignocellulose substrate in order to change materialqualities that include density, porosity and flexural capacities. Afterbeing dried, the material becomes more resilient if treated with a wax,oil or other types of available sealants. The fungal molded shapes 142derive their particular strength from the density of mycelial mass canalso be effected by the thickening of the substrate skin. Thesequalities can be achieved through many factors, one being the gas levels(O², CO², etc.) in the immediate growing environment of the growingfungus. The addition of selected molds, algae or other microorganism tothe immediate environment in which the fungus is growing creates acondition in which the growing fungal substrate forms a tough skin or“blister” on its surface, and otherwise become much denser as a reactionto the secondary gases and metabolites produced from said addedorganisms. Fungal bricks grown in association with algae exhibit thehabit of growing rhizomorphic formations, wherein a tough, hardenedcasing is generated, and is similar to thermoplastics in hardness anddurability. Rhizomorphs are large, tubular collectives of hyphal cells,which form thick parallel strands of in fungal mycelia, which upondrying resemble the shells of beetles and other insects who comprisetheir exoskeleton from densely woven chitin.

Continuing with FIG. 5, the exemplary block shown above may optionallybe combined with secondary materials. In certain embodiments, the fungalmycelium is allowed to grow into a laminate surface, or optionally alaminate surface is affixed to dried fungal mycelium, through anysuitable means such as glue. The laminate may serve to protect thefungal surface from natural decomposition, may offer increased strengthwhen a sheet of laminate is placed between two fungal mycelium surfaces,and can serve to prevent an active mycelium to mycelium relationshipbetween two surfaces that without the laminate would otherwise be incontact. Additional layers of fungal mycelium may be joined together,each with laminate between them, to offer additional qualities, such ashigh impact resistance and bulletproofing.

FIG. 6 illustrates the plurality of fungal molded shapes 142incorporated with a plurality of dowels 146 to create structuralconnections in accordance with the exemplary embodiment of the presentinvention. The plurality of dowels 146 may be cross-linked with wire orother binding materials, compressing the fungal molded shapes 142together. The dowels 146 act as a registration system as well asmaterials for facing or skinning. Bamboo, steel, or any other tensilematerials may be used instead of wood dowels. In this case, a doublelayer of fungal molded shapes are stacked offset, with the guidingchannels in the fungal molded shapes holding dowels in place.

FIG. 7 illustrates the creation of an arch 152 by placing the pluralityof fungal molded shapes 142 in proximal contact with one another to forman organic bond in accordance with the exemplary embodiment of thepresent invention. The fungal molded shapes 142 formed into a complexcomposite shape utilizing the organic weld. The fungal molded shapes mayalso be joined to form a structure in the form of the arch 152. Thefungal molded shapes 142 may be joined together and adhered to oneanother to form an organic weld between any given numbers of fungalmolded shape 142. Sticking two fungal molded shapes 142 is accomplishedby stationing one on top of the other while the material is still alive,that is, before it has dried out. Once connected, the fungal moldedshapes may be left alone in a nominally controlled environment, until astrong bond is formed. Although the fungal molded shapes 142 shown inthe exemplary embodiment take the form of individual shapes, a set offewer or more blocks can similarly be used to form a structure. Fewerblocks makes for a simpler system, reducing the number of casts thatmust be made, while a greater number of blocks allows for greatercustomization and variation in design.

FIG. 8 illustrates the creation of a wall portion 162 by placing theplurality of fungal molded shapes 142 in proximal contact with oneanother to form an organic bond in accordance with the exemplaryembodiment of the present invention. The fungal molded shapes 142 formedinto a complex composite shape utilizing the organic weld. The fungalmolded shapes may also be joined to form a structure in the form of awall, a portion of which is shown as wall portion 162.

The organic welding is accomplished by action of the fungus itself. Ifgrown in optimized conditions, the fungus may be induced to fuse withany cloned mass of its own tissue. This is well known, and described inU.S. Pat. No. 5,074,959 to Yamanaka. By virtue of this fusing propertyof the fungus it is possible to manufacture building elements that aredesigned to fuse together, which after drying may be machined, treated,and formed as one might a wood or composite board. The method disclosedby the current application forms the fungal molded shapes 142 in such away as to maximize surface contact with any fungal molded shape, whichfacilitates and encourages the fusing process. The process of fusingfungal molded shapes 142 together simply requires stacking individualforms in a manner such that there is direct surface contact between thediscrete forms. Environmental factors may be altered to affect the speedand quality of the organic weld. These environmental factors may includephoto periods, temperature, moisture levels, and suppression of theambient microbial life in the growing space. Fast duration compaction ofprecolonized substrate may result in a densely packed form that hasabsorbed an aqueous gel agent deep within the fungal mycelium. Thisaqueous gel could be seeded with a solution of time release peroxisomiccompounds that will induce specific curves of gas concentrationsthroughout the growing form, enabling a more vigorous mycelia growthrate and reducing the risks of secondary infection by anaerobicmicrobes.

The density of the mycelium and the material properties of the buildingmaterials may be varied by controlling various inputs to themanufacturing process. By controlling these inputs, it is possible toachieve stronger and more finely resolved features in objects composedfrom this dried somatic substance. These controlling inputs include thesize and form of the lignocellulosic ingredients that comprise thesubstrate material. Different shapes and consistencies of substratematerial will alter the composition and qualities of the cultivatedobjects. Other controlling inputs include the environmental conditionsin which the fungi are grown. Increased material densities can also beachieved by mechanically concentrating the substrate in resilient anddurable molds, and also through pressing fully colonized livingmaterials into secondary molds to achieve greater material densities andfiner resolutions. Living material treated and re-combined in thismanner continues to grow, and can be shaped into artifacts with fineresolutions and surface qualities.

FIG. 9 illustrates secondary materials 154 incorporated into the fungalmycelium 156 to create structural connections in accordance with theexemplary embodiment of the present invention. Secondary materials 154are incorporated into the fungal mycelium 156 to further createstructural connections, mechanical reinforcements, and interfacingswithin and on the surface of the molded fungal shape. These insertedsecondary materials can then be incorporated within the living mycelium.The secondary materials 154 may be but are not limited to woven bamboo,sisal and other organic materials. These secondary materials arepreferably stacked between the fungal mycelium 156, but may beintegrated in using other methods as known in the art. These stackedsheets of secondary materials are then incubated, grown, and fusedtogether with the mycelium. Secondary materials may be insertedpartially from one surface to the middle, or can fully pierce the samplealong any desired axial path. These layers of thin organic material maybe grown together in sheets or pressed and formed into molds withspecific shapes. These reinforcements can change skin densities,reinforce adhesion, structurally reinforce assembly components, andcreate building elements with interfaces and connection points thatinclude incorporated fixturing and fastening elements. The myceliumadded to this organic substrate will bond the layers together into asolid laminate.

When pressure is applied such as is shown in FIG. 8 by arrow 158, thebonding becomes even stronger between the secondary materials 154 andthe fungal mycelium 156.

In another instance, thin rods and slats of bamboo, rattan, or othermaterial may be layered near the top and bottom surface of thesubstrate, each set at right angles to the other; and then thiscross-grained laminate may be pressed into a secondary form and allowedto grow. The bamboo may also act as a spanning reinforcement, makingbricks or other forms that can be load bearing and serve otherstructural capacities. In another instance, rope or other tensilematerial may be used to reinforce a structural element. These, and otherincorporated elements may change the properties of the dried andfinished object, altering the shear and tensile strengths in ways thatare similar to the tuning of composite materials. In this way it ispossible to design and grow organically derived structural elements, andthese elements may be engineered with specific material tolerances andcapabilities.

FIG. 10 illustrates a two-tabbed fixturing element 164 incorporateddirectly into the fungal molded shape 142 in accordance with anotheraspect of the exemplary embodiment the present invention. When thecompressive forces are applied as exemplarily shown in FIG. 9, thefixturing element 164 becomes even more tightly embedded in the fungalmolded shape than would be possible using conventional technology. Agrown and dried fungal molded shape 142 of somatic material isincorporated with the two-tab fixturing element 164. The fungal moldedshape 142 may be incorporated with the structural elements with portionsextending out from the fungal material, and may be designed as anincorporated fastening or fixturing element. The fastening or fixturingelements may include holes, tabs, hoops, locks, pegs, or any othermechanical device for anchoring, connecting or interfacing a fungalobject. Through the combination of adding amendments to the substrateand adding structural elements within and between grown and growingfungal molded shapes, various building material properties may bedeveloped. It is to be understood that the disclosed exemplaryembodiments are illustrative merely of the concept and general practiceof incorporating fastening or fixturing elements, and are not intendedto limit the scope of breadth of the claimed subject matter.

In another alternate embodiment where the stronger and denser buildingblocks are created by use of pressure and the pasteurized substrate isfirst colonized and allowed to grow until fully colonized, the substratepreferably has a weight ratio of approximately 2 pounds of water perpound of dry weight sawdust, ground nutshells, or corn cobs. After thesubstrate is fully colonized, it is crumbled and broken apart, filteredby size, and then compressed under pressure into molds of desired shapeand size. It is noted that compressing the smallest particles of fungalmycelium using this technique resulted in the strongest material. Thebroken up and filtered fungal mycelium is compressed with appliedpressure between 300-500 psi. If the material is over-compressed, upondecompression the substrate will expand, absorbing air and any othermaterial in the mold. By adjusting the pressure applied, the grain size,and the hydration of the substrate 170 before compression, it ispossible to vary the density of the final product and adjust variousmaterial qualities. After compression, the material may be left in themold or may be immediately turned out onto a secondary growth surface.After the compressed material is turned out of its mold, it may requirea minimum of three days with proper environmental adjustments for themycelium to reestablish and connect back together resulting in a strongfinal product. The turned out material may be allowed more than threedays after compression depending upon desired final surface qualitiesand other tunable variables.

In yet another embodiment, the fungal mycelium is partially dried andrehydrated while undergoing the pulsed application of linear pressure,thereby allowing for a much denser and thinner material than iscurrently manufacturable, with possible applications replacing highimpact.

In association with any of the drying phases, stressing and reforming ofthe original sample may induce stress fractures, cracks and deformitiesin the sample. These can then pressed (with or without rehydration) sothat the internal mycelium can regrow through these fractures, cracksand deformities, structurally reinforcing the sample. The above canhappen without the application of pressure as well.

FIG. 11 illustrates a plurality of fungal molded shapes 170 formed withcast void spaces 172 in accordance with the alternate embodiment of thepresent invention. The fungal molded shape 170 may be grown withchannels, void spaces, raised features, and registration artifactscapable of coupling the plurality of fungal molded shapes to otherobjects. By utilizing pressure compression method, it is possible to useone and two part molds with drop pins and void spaces. It would also bepossible to construct any type of multiple part molds for compressingthe fungal mycelium in this way, similar to the molds used for injectionmolding. Using this method, it is possible to create beams and otherelements of significant size. Additionally, it is possible to combinethis high-pressure embodiment with the above-disclosed embodiments,which incorporate additional materials such as bamboo or rope into thefinal product.

FIG. 12 depicts four images taken as steps in a process from left toright, wherein a vessel 180 is depicted holding a fungal molded shape142, then a piston 181 is shown compressing said fungal molded shape 142such that outgassing occurs, then upon release of the piston 181ingassing is apparent as the fungal molded shape 142 naturally reboundsor expand to some extent, resulting in the final image on the right handside of the figure. Not shown, if the area around the vessel weresurrounded with an agent, either gaseous or liquid, it would be taken upby the expanding fungal form. Importantly, this method allows gas andliquid agents to be introduced to a fungal molded shape without anymechanical injection. Instead, negative pressure from the expandingfungal form causes the form to naturally uptake agents surrounding it.Although in this image a vessel is shown, compression could occur inother manners, such as by a roller as the fungal body moves down acontinuous assembly line or conveyer belt. By surrounding the fungalbody with the agent (either liquid or gas) immediately after compressionis released, the fungal body will uptake the agent.

The above-mentioned partial drying with rehydration that includessuspended liquid/solid/gas/biological agents that may create aprotective layer against infection for the mycelium within the sample.Possible applications may be used in growing two bricks together withinenvironments that do not have adequate environmental controls, with theprotective layer keeping unwanted living agents from infecting thesample. This protective layer can be rendered inert or permeable to theinternal mycelium through the application of water or other hydratingagents. Building on site of complex fungal structures would be possiblewith this. Suspended agents may include the following as singularagents, in combination, or in successive application: Xanthan gum,Locust bean gum, Guar gum in combination with calcium to form gellingcross links, other commercially available protective food gums,Carboxylmethylcellulose, Carboxylmethylcellulose in combination withpotassium sorbate, alcohols of various types, including but not limitedto, and in purified or gelled suspensions, calcium, chlorine,chlorophenols, benzalkonium chloride, ammonia, peroxisomic compounds,silver and silver compound in solution, algae and other living agents.

In any of the above embodiments, stress may be applied to the growing ordrying components to prompt further action from the fungus. Forinstance, stress pressure may be applied to a fungal molded shape thatapproximates the real world pressure that fungal shape is likely toreceive when used as a part of a structure. Given enough pressure,cracks or fissures will form. Here, pressure may be released and thehyphae may be allowed to continue to grow, thereby not only filling inthe cracks, but also causing new material to be formed, and henceincreasing the strength, right in the region where it formerly was theweakest. As another example of method components that need not be takenin the order presented in exemplary embodiment FIG. 1, stress pressuremay be applied to the lignocellulose based medium, prior to inoculation.Further, the stress pressure may be applied whether a mold is used ornot. For instance, in the continuous feed embodiments, stress pressure,such the pulling apart of, twisting of, or compressing of the fungalmycelium may occur. Again, any weak points that form cracks or fissureswill be grown over with new hyphae such that the fungal mycelium becomesstronger in the areas where it was formerly weaker.

All of the above discussed methods and embodiments offer the advantageof transforming agricultural or other waste into a durable industrialgrade material that can serve a wide range of manufacturing andconstruction applications. The fungal material can be used to replaceplastic or wood and may be combined with bamboo and other renewablematerials to create hybrid composites. The fungal material is producedusing considerably less energy than is required to create comparablehybrid composites. Additionally, the fungal material is biodegradable,durable and tunable. The building materials are fire resistant, waterresistant, mold resistant and possess good insulative properties. Themethods discussed herein make use of agricultural waste material, whichmay be effectively turned into high quality construction material atvery low energy and production cost.

All of the above mentioned embodiments of the fungal material andvariations thereon may be used for construction, packaging, and a widevariety of other uses. Such uses may include utility and application inenvironmentally sensitive areas for the purpose of creating any type oftemporary or permanent artifact, particularly in projects focused onremediation or in areas particularly sensitive to industrial impact. Thefungal material may be used where planned obsolescence for an object orlimited use is desired, such as for consumer electronics casings andcomponents in furniture. The fungal material may also be used to createbiodegradable vessels, shelters, and intermediary forms used in landreclamation and conservancy. Once a structure that is composed from thismaterial no longer serves a utility or purpose the structure might bebroken down into smaller pieces on site and left to biodegrade. Thefungus may also be grown into terraced forms such as the ones that areused in civil engineering and landscaping. The fungus may be employed toshape contoured earth forms, to create diversion streams, embankments,water elements, and retaining walls. It is known that mycelium have theability to help clean nitrogen and other reactive compounds from soiland other organic substrates, and both strengthen soil composition andare a strong contributing factor towards the general health of theliving ecologies that they are a part of. While serving a functional orstructural purpose, materials used for these ends might also be used fornovel applications in bioremediation. Mycelium of fungal species haveevolved the ability to utilize super oxidative compounds and otherstrong lysosomic agents that are used to break lignocellulose intometabolizable sugars and other nutrients. The fungi are characterized bythis transformational ability, and are the primary decomposers of theworld's toughest organisms, organs, tissues, cells and componentmolecules. For these and other reasons the saprophytic fungi are capableof transforming, neutralizing and breaking down a wide range of biotoxicmolecules and other noxious compounds. It has been recorded that somespecies of mushrooms have been grown on a lignocellulose compoundsaturated with used motor oil. The fungi are able to breakdown thecomplex molecular chains that are normally difficult to break down, suchas macromolecules, biopolymers and certain organic compounds. For thisreason it is believed that semi living structures can be incorporated asbeneficial attributes and materials for bioremediation projects as wellas for use in cleaning brown and grey field pollutants.

It is possible through careful and precise adjustments to create fungalblocks and fungal building materials that perform beyond those in theprior art, and may be prepared more simply and with less equipment thanthose in the prior art. Using methods described herein, fungal formscompressed around embedded forms exhibited adhesion strength at leastfour times stronger than a control.

The process is dependent on the frequency, duration and amount ofpressure that is applied to the growing mycelium, and can be practicedin orchestration with several other variables to generate a wide varietyof structural qualities such as toughness, flexibility, dynamicresistance, etc. In one instance, blocks and other constructionmaterials may be formed in a way that placement in a mold and forsolidification is not required.

Using the methods described herein, building blocks larger than thoseknown in the prior art may be grown. Indeed, no apparent scalelimitation was found in development. Furthermore, these forms may bemade in a way that they do need to be placed in a mold for shaping andto solidify.

Using the methods described surrounding the multi-layering of pieces oflaminated fungal mycelium, improved resistance to impact was found. Inone instance, 8 layers of 1″ thin pieces of grown fungus were gluedtogether with paper board squares between each layer, such that theentire structure was 8.5″ deep when glued together. In testing a hollowpoint bullet fired from a .38 came to rest within the last layer offungus. FIG. 6. Depicts one such wall, which may be used for impactresistance. The wall exhibits sufficient strength to act as a loadbearing wall within a building.

It is possible through careful and precise adjustments to create fungalblocks and fungal building materials that perform beyond those in theprior art, and may be prepared more simply and with less equipment thanthose in the prior art. Using methods described herein, fungal formscompressed around embedded forms exhibited adhesion strength at leastfour times stronger than a control. Further, these embedded forms can beprocessed and dried more quickly than other methods, and are achievedwithout greater substrate density or additional agents.

Further expected use of the methods described herein are in developingand rural settings, where the simplicity of tools and processes in theart in those areas will still allow for the generation of a wide rangeof durable, long lasting and resilient materials from lignocellulosewaste sources. The fungal material finds potential uses in gardening andlandscaping, civil engineering, including the regeneration of fungalmycelium through the timed germination and dispersal of companion plantsand other life forms that may be embedded within a somatic form. Thefungal structures can act as animal shelter, ground cover and generalinert environmental scaffolding. Moreover, this fungal material may alsobe used to create strong lightweight shells and forms that may be usedin the manufacture of boats, furniture, and other consumer or commercialproducts which currently employ cardboard honeycomb, fiberglass,plastics or other strong lightweight materials to create structuredforms such as molded decorative tiles, molding, temporary advertisinginstallations, and panel relief forms. The somatic substance may also beemployed as a replacement for high impact thermoplastics, such as thecasing shells for consumer electronics, components for industrialequipment and home appliance, and vehicle bumpers. Additionally, thesomatic material has excellent compressive qualities and can absorbblunt forces, disperse seismic waves, and damp acoustic signals.

The foregoing description of the preferred embodiment of the presentinvention has been presented for the purpose of illustration anddescription. It is not intended to be exhaustive or to limit theinvention to the precise form disclosed. Many modifications andvariations are possible in light of the above teachings. For instance,the inoculation or the pasteurization of the fungal substrate may occurafter placement of the fungal substrate into the mold. Further,innovations in pasteurization, microbial suppression, or clean roomdesign and control may be integrated into the manufacture process.Batch, continuous, or segmented production methods may also be employedto manufacture the fungal molded shapes. It is intended that the scopeof the present invention not be limited by this detailed description,but by the claims and the equivalents to the claims appended hereto.

I claim:
 1. A molding system for forming an inoculated lignocellulosebased medium into a fungal molded shape, the molding system comprising:a. a vessel within which environmental conditions are regulated, thevessel comprising an inoculated lignocellulose based medium capable ofsupporting growth of saprophytic fungi without any secondary organismsdisplacing the process through infection; b. a secondary organicmaterial layered near the top and bottom of the inoculatedlignocellulose based medium; c. a hard mold containing the flexiblevessel; and d. a compressive system for applying a primary compressivepressure of at least 10 PSI to the lignocellulose based medium such thatit takes on a fungal molded shape.
 2. The molding system of claim 1wherein said flexible vessel environmental conditions are between 55 and90 degrees Fahrenheit.
 3. The molding system of claim 1 wherein saidflexible vessel environmental conditions include a hydration level ofbetween 44% and 66%.
 4. The molding system of claim 1 wherein saidvessel comprises a flexible breathable filter membrane or flexiblebreathable filter membrane patch allowing gas exchange while preventingthe passage of bacteria and microorganisms.
 5. The molding system ofclaim 1 wherein said fungal molded shape comprises an outer surface ofmycelium.
 6. The molding system of claim 1 further comprising aplurality of fungal molded shapes in proximal contact with one another.7. The molding system of claim 6 wherein said fungal molded shapescomprise an outer surface of mycelium.
 8. The molding system of claim 1wherein said fungal molded shape has a weight of which at most 15% ofsaid weight is made up of water.
 9. The molding system of claim 1wherein said fungal molded shape comprises fungal mycelium.
 10. Themolding system of claim 9 wherein the fungal mycelium is in contact withsecondary materials.
 11. The molding system of claim 1 wherein saidfungal molded shape has a weight of which at most 15% of said weight ismade up of water.
 12. The molding system of claim 1 wherein thecompressive system is further for applying a secondary compressivepressure of at least 100 PSI.
 13. The molding system of claim 1 whereinsaid primary compressive pressure is of at least 500 PSI.
 14. A moldingsystem comprising: a. a first inoculated lignocellulose based medium; b.a second, as-grown inoculated lignocellulose based medium; c. aperforation layer between said first and second media; and d. wherebysaid second, as-grown inoculated lignocellulose based medium contains init a cellulosic or non-cellulosic fabric.
 15. The molding system ofclaim 14, wherein the first inoculated lignocellulose based medium iswithin a vessel in which environmental conditions are regulated.
 16. Themolding system of claim 15 wherein the vessel is within a hard mold. 17.The molding system of claim 14 wherein the grown inoculatedlignocellulose based medium is capable of supporting growth ofsaprophytic fungi without any secondary organisms displacing the processthrough infection.
 18. The molding system of claim 14 wherein the secondinoculated lignocellulose based medium is dry and biologically inert.19. The molding system of claim 14 wherein the second inoculatedlignocellulose based medium is a compressed form of mycelium fungi. 20.The molding system of claim 4 wherein the second, as-grown inoculatedlignocellulose based medium is selected from the group of fungal spawnconsisting of: Ganoderma lucidem, Ganoderma tsugae, Ganodermaoregonense, Fomes fomentarius, Trametes versicolor and Piptoporousbetulinus.